High liquidus viscosity bioactive glass

ABSTRACT

Methods of making a bioactive glass fiber include forming a melt of a glass composition including: 50 to 70% SiO2; 0.1 to 10% Al2O3, 5 to 30% Na2O, 0.1 to 15% K2O, 0.1 to 15% MgO, 0.1 to 20% CaO, and 5 to 10% P2O5, based on a 100 wt % of the glass composition. The melt has a viscosity of from 200 Poise to 2,000 Poise. Methods include drawing the melt into a drawn glass fiber. Bioactive glass compositions include: 60 to 70% SiO2; 15 to 30% Na2O, 5 to 15% K2O, 1 to 10% CaO, and 5 to 10% P2O5, based on a 100 wt % of the glass composition.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 16/202,952 filed on Nov. 28, 2018, which claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Patent Application No. 62/591,446 filed Nov. 28, 2017, the content of which is incorporated herein by reference in its entirety.

The present application is related commonly owned and assigned USSN Provisional Application Nos., filed May 25, 2016:

62/342,384, entitled “BIOACTIVE ALUMINOBORATE GLASSES”;

62/342,377, entitled “MAGNETIZABLE GLASS CERAMIC COMPOSITION AND METHODS THEREOF”;

62/342,381, entitled “LITHIUM DISILICATE GLASS-CERAMIC COMPOSITIONS AND METHODS THEREOF”;

62/342,391, entitled “BIODEGRADABLE MICROBEADS”; and

62/342,411, entitled “BIOACTIVE GLASS MICROSPHERES”; but does not claim priority thereto.

The present application is also related commonly owned and assigned USSN Application Nos.:

62/591,423 filed Nov. 28, 2017, entitled “BIOACTIVE GLASS COMPOSITIONS AND METHODS OF TREATING DENTIN HYPERSENSITIVITY”;

62/591,438, filed Nov. 28, 2017, entitled “CHEMICALLY STRENGTHENED BIOACTIVE GLASS-CERAMICS”; and

62/591,429, filed Nov. 28, 2017, entitled “BIOACTIVE BORATE GLASS AND METHODS THEREOF”, filed concurrently herewith, but does not claim priority thereto.

The entire disclosure of each publication or patent document mentioned herein is incorporated by reference.

BACKGROUND

The disclosure relates to a bioactive glass having a high liquidus viscosity, and to methods of making and using the bioactive glass.

SUMMARY

In embodiments, the present disclosure provides bioactive glass compositions. The bioactive glass compositions can comprise, for example, in weight percentage (wt %), 50 to 70% SiO₂, 0.1 to 10% Al₂O₃, 5 to 30% Na₂O, 0.1 to 15% K₂O, 0.1 to 15% MgO, 0.1 to 20% CaO, and 5 to 10% P₂O₅, based on 100 wt % total.

In embodiments, the disclosure provides bioactive glass compositions having components, for example, in weight percentage, of from 60 to 70% SiO₂, of from 15 to 30% Na₂O, of from 5 to 15% K₂O, of from 1 to 10% CaO, and of from 5 to 10% P₂O₅, i.e., free of Al₂O₃, MgO, or both.

In embodiments, the present disclosure provides bioactive glass compositions having a relatively high viscosity, which viscosity enables different or alternative forming methods.

In embodiments, the present disclosure provides bioactive glass compositions having excellent biocompatibility.

In embodiments, the present disclosure provides bioactive glass compositions that can be continuously drawn into glass fibers having a diameter, for example, of from 1 to 100 microns.

BRIEF DESCRIPTION OF THE DRAWINGS

In embodiments of the disclosure:

FIGS. 1A and 1B show SEM images at 500 micron (1A) and 50 microns (1B) scales, respectively, of glass fibers produced using a down-draw process from disclosed Composition 5 in Table 1.

FIGS. 2A to 2D show optical images of cell morphology from live/dead cells assay.

DETAILED DESCRIPTION

Various embodiments of the disclosure will be described in detail with reference to drawings, if any. Reference to various embodiments does not limit the scope of the invention, which is limited only by the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not limiting and merely set forth some of the many possible embodiments of the claimed invention.

In embodiments, the disclosed compositions, articles, and methods of making and using provide one or more advantageous features or aspects, including for example as discussed below. Features or aspects recited in any of the claims are generally applicable to all facets of the invention. Any recited single or multiple feature or aspect in any one claim can be combined or permuted with any other recited feature or aspect in any other claim or claims.

Definitions

“Liquidus temperature” (T_(L) or T_(liq)) refers to the boundary temperature at which a first crystalline compound is formed when the glass specimen is held at a specific temperature gradient over the gradient's entire length for a period of time necessary to obtain a thermal equilibrium between the crystalline and glassy phases (see ASTM C829-81). A liquidus temperature of a glass can be measured using the gradient furnace method specified by ASTM C829-81.

“High temperature viscosity” refers to (no the measure of the resistance of a liquid to gradual deformation by shear stress or tensile stress. The viscosity of glass above its softening point can be measured using a platinum alloy spindle immersed in a crucible of molten glass as specified by ASTM 965-96. Liquidus viscosity refers to the glass viscosity at the corresponding liquidus temperature.

“Include,” “includes,” or like terms means encompassing but not limited to, that is, inclusive and not exclusive.

“About” modifying, for example, the quantity of an ingredient in a composition, concentrations, volumes, process temperature, process time, yields, flow rates, pressures, viscosities, and like values, and ranges thereof, or a dimension of a component, and like values, and ranges thereof, employed in describing the embodiments of the disclosure, refers to variation in the numerical quantity that can occur, for example: through typical measuring and handling procedures used for preparing materials, compositions, composites, concentrates, component parts, articles of manufacture, or use formulations; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of starting materials or ingredients used to carry out the methods; and like considerations. The term “about” also encompasses amounts that differ due to aging of a composition or formulation with a particular initial concentration or mixture, and amounts that differ due to mixing or processing a composition or formulation with a particular initial concentration or mixture.

“Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.

The indefinite article “a” or “an” and its corresponding definite article “the” as used herein means at least one, or one or more, unless specified otherwise.

Abbreviations, which are well known to one of ordinary skill in the art, may be used (e.g., “hr” or “hrs” for hour or hours, “g” or “gm” for gram(s), “mL” for milliliters, and “rt” for room temperature, “nm” for nanometers, and like abbreviations).

Specific and preferred values disclosed for components, ingredients, additives, dimensions, conditions, times, and like aspects, and ranges thereof, are for illustration only; they do not exclude other defined values or other values within defined ranges. The composition and methods of the disclosure can include any value or any combination of the values, specific values, more specific values, and preferred values described herein, including explicit or implicit intermediate values and ranges.

In embodiments, the disclosure relates to a bioactive glass having an ability to bond strongly with hard and soft mammalian tissue, and to foster the growth of bone and cartilage cells (see Rahaman, et al., Bioactive glass in tissue engineering, Acta Biomater 2011, 7: 2355-2373). Bioactive glasses have been reported to release ions that activate expression of osteogenic genes, and stimulate angiogenesis (see Rahaman, supra.). Example commercial products including, for example, Perioglas® (NovaBone Products LLC, Alachua, Fla.), Novabone® (NovaBone Products LLC), or NovaMin® (Glaxo-Smith-Kline, UK) are based on bioactive glass particles (see Jones, Review of bioactive glass: From Hench to hybrids. Acta Biomater 2013, 9: 4457-4486). The low liquidus viscosity of traditional bioactive glasses limited their forming capability (see Q. Fu, et al., Bioactive Glass Innovations Through Academia-Industry Collaboration. Int J Appl Glass Sci, 2016, 7: 139-146). For example, the benchmark bioactive glass 45S5 composition has a liquidus viscosity of 24 poise at 1185° C. (Control 1 herein in Table 1) while another well-studied glass 13-93 glass composition has a liquidus of 200 poise at 1145° C. (Control 2 herein in Table 1). In comparison, traditional soda lime silicate glass has a liquidus viscosity of about 10,000 poise at 1010° C. (see Q. Fu, et al., supra.; and Wallenberger, et al., The Liquidus Temperatures; Its Critical Role in Glass Manufacturing, Int J Appl Glass Sci, 2010, 1:151-163).

In embodiments, the disclosure provides a bioactive glass composition comprising:

50 to 70% SiO₂;

0.1 to 10% Al₂O₃,

5 to 30% Na₂O,

0.1 to 15% K₂O,

0.1 to 15% MgO,

0.1 to 20% CaO, and

5 to 10% P₂O₅, based on a 100 wt % of the composition.

In embodiments, the liquidus viscosity of the composition can be, for example, of from 200 to 5,000 poise.

In embodiments, the bioactive glass composition can have, for example, a biocompatibility of at least one of, for example, a proliferation of a live cell line on the surface of the bioactive glass, a continuous cell number increase of from 0 to 7 days, or a combination thereof.

In embodiments, the composition as a drawn fiber form factor can have a diameter of from 1 to 100 microns.

In embodiments, the disclosure can provide, for example, a dental formulation, a wound healing formulation, a bone growth or restoration formulation, and like useful formulations.

In embodiments, the composition can further comprise formulation ingredients, for example, a carrier in an amount of from 5 to 300 wt % by superaddition to the bioactive glass composition to form a bioactive glass formulation. The carrier can be, for example, any known solid, liquid, gel, or a combination thereof. Formulation of the bioactive glass composition with a carrier can provide many advantages, such as pre-selected dose levels, pre-selected concentrations, stabilized mixtures or suspensions of the bioactive glass and an adjuvant, and like advantages.

In embodiments, the carrier can be, for example, one or more ingredients selected from: an abrasive, a humectant, i.e., an anti-drying agent such as glycerol, sorbitol, xylitol, 1,2-propylene glycol, polyethyleneglycol, and like compounds, a flavorant, a colorant, an antibacterial agent, a surfactant, a whitening agent, and other like suitable ingredients known in the art, or a mixture thereof.

In embodiments, the disclosure provides a dental formulation composition wherein the suitable carrier comprises one or more forms selected from: a gum, a paste, a powder, a toothpaste, a mouthwash, a poultice, a tea, a sucker, a spray, and like forms, or a mixture thereof

In embodiments, the disclosure provides a preferred bioactive glass composition comprising:

60 to 70% SiO₂,

15 to 30% Na₂O,

5 to 15% K₂O,

1 to 10% CaO, and

5 to 10% P₂O₅, based on a 100 wt % of the composition.

In embodiments, the preferred bioactive glass composition can be free of Al₂O₃, MgO, or both.

In embodiments, the preferred bioactive glass composition can further comprise, for example, a carrier in an amount of from 5 to 300 wt % by superaddition to the bioactive glass composition to form a bioactive glass formulation as mentioned above.

In embodiments, the disclosure provides a method of making a bioactive glass fiber comprising, for example:

forming a melt of the glass composition comprising:

50 to 70% SiO₂;

0.1 to 10% Al₂O₃,

5 to 30% Na₂O,

0.1 to 15% K₂O,

0.1 to 15% MgO,

0.1 to 20% CaO, and

5 to 10% P₂O₅, based on a 100 wt % of the composition, until the melt has a viscosity of from 200 to 2,000 poise; and drawing the melt into a fiber.

In embodiments, the drawn glass fiber can have, for example, a diameter of from 1 to 100 microns.

In embodiments, drawing the melt into a fiber can be accomplished, for example, batch-wise, semi-continuously, or continuously.

In embodiments, the temperature of the glass in the melt can be, for example, from 1050 to 1,200° C., and is above the glass liquidus temperature by from 10 to 200° C.

The present disclosure is advantaged is several aspects, including for example:

The disclosed bioactive glass compositions have much higher liquidus viscosities such as at least ten times higher compared to a benchmark 45S5 bioactive glass, which makes the disclosed bioactive glass compositions more suitable for an industrial manufacturing platform.

The disclosed bioactive glass compositions have excellent biocompatibility as demonstrated by, for example, in vitro cell culture studies. These studies demonstrated the desired capability to support cell attachment and growth over a period of up to 7 days.

The disclosed bioactive glass compositions can be continuously drawn into glass fibers having a diameter of from 1 to 100 microns from a glass melt.

In embodiments, the present disclosure provides bioactive glass compositions that have demonstrated high liquidus viscosity and excellent biocompatibility. The improved liquidus of the disclosed compositions permits, for example, glass fibers of from 1 to 100 microns to be continuously drawn.

In embodiments, the disclosed glass, for example, in a batch composition or a finished glass, comprises, for example, in weight percentage, of from 50 to 70% SiO₂, of from 0.1 to 10% Al₂O₃, of from 5 to 30% Na₂O, of from 0.1 to 15% K₂O, of from 0.1 to15% MgO, of from 0.1 to 20% CaO, and of from 5 to 10% P₂O₅. Example compositions are listed in Table 1.

In embodiments, a more preferred composition can be, for example, in weight percentage, of from 60 to 70% SiO₂, of from 15 to 30% Na₂O, of from 5 to 15% K₂O, of from 1 to 10% CaO, and of from 5 to 10% P₂O₅. These glasses can typically be melted at a temperature below 1300° C., and in certain embodiments below 1400° C., making it possible to make melts in a relatively small commercial glass tank.

Table 1 lists exemplary as-batched compositions 1 to 8, and control 1 (45S5) and control 2 (13-93).

TABLE 1 As-batched compositions. Composition > Oxides Contro Contro (wt %) 11 12 1 2 3 4 5 6 7 8 SiO₂ 45 53 65.6 64.4 64.4 63.2 62.1 64.4 63.2 61.0 Na₂O 24.5 6 22.5 22.1 22.1 21.7 21.3 22.1 21.7 20.9 K2O 0 12 0.0 0.0 1.8 3.6 5.3 0.0 0.0 3.4 CaO 24.5 20 4.6 4.5 4.5 4.4 4.3 4.5 4.4 4.3 MgO 0 5 0 0 0 0 0 1.8 3.6 3.4 P₂O₅ 6.0 4 7.4 9.1 7.3 7.1 7.0 7.3 7.1 6.9 T_(liq) (° C.) 1185 1145 1105 1195 1005 1015 990 1070 1090 1040 η_(liq) (poise) 24 200 765 335 657 1679 2000 1131 883 1230

The liquidus viscosity (η_(liq)) of presently disclosed compositions can be, for example, up to 2,000 poise (Table 1), which makes them compatible with a wide range of forming methods including pressing, blowing, casting, thin rolling, floating, and like methods. This formability enables different forming factors from the disclosed compositions. These glasses can be processed by different techniques into, for example, powder, fibers, beads, sheets, or 3-D scaffolds. A glass powder can generally be prepared by, for example, jet milling or ball milling of glass frits; short fibers can be made by, for example, melt spinning or electric spinning; beads can be produced by, for example, flowing glass particles through a vertical furnace; sheets can be made by, for example, using thin rolling, floating or fusion-draw processes; and scaffolds can be produced by, for example, using rapid prototyping, polymer foam replication, particle sintering, and like methods. Disclosed glasses of desired forms can be used, for example, to support cell growth, soft and hard tissue regeneration, stimulation of gene expression, angiogenesis, and like applications.

Continuous fibers can be easily drawn from the claimed glass compositions. Fiber can be formed using a directly heated (i.e., electricity passing directly through) platinum bushing. Glass cullet is loaded into the bushing, and heated until the glass melts. Temperatures are set of from 1000 to 1200° C. to achieve a desired glass viscosity of, for example, from 200 to 2000 poise, from 335 to 2000 poise, from 200 to 1500 poise, for example, less than 1,000 poise, allowing a drip to form on the orifice in the bushing. The bushing size can be selected to create a restriction that influences possible fiber diameter ranges. The drip can be manually pulled to begin forming a fiber. Once a fiber is established the fiber can be connected to a rotating pulling and collection drum to continue the pulling process at a consistent speed. Using the drum speed (or revolutions per minute RPM) and glass viscosity, the fiber diameter can be manipulated, i.e., varied and controlled. Generally, the faster the fiber pull speed, the smaller the fiber diameter. It is significant to keep the glass temperature above the glass liquidus temperature so that devitrification is eliminated (or reduced) on the bushing orifice (see Yue, et al., Fiber Spinnability of Glass Melts, Int. J. Appl. Glass Sci. 2017, 8: 37-347). When devitrification (i.e., crystallization) begins to form, the fiber will tend to break due to the slow glass flow or the loss of glass flow completely. Glass fibers having diameters of from 1 to 100 microns can be drawn continuously from a glass melt (see FIGS. 1A and 1B). Alternatively, test fibers can also be created using an updraw process. In this process, fibers are pulled from a glass melt surface sitting in a box furnace. By controlling the viscosity of the glass, a quartz rod is used to pull glass from the melt surface to form a fiber. The fiber can be continuously pulled upward to increase the fiber length. The pull up velocity of the rod determines the fiber thickness.

Excellent biocompatibility was demonstrated in each of the example glass Compositions 1 to 8 in Table 1. Cell attachment and growth were clearly observed on the surfaces of example glass articles made from the disclosed compositions, and in the TCT culture wells. No visible difference in cell morphology was observed between the disclosed compositions and the TCT culture wells. FIGS. 2A to 2D show optical images of cell morphology from live/dead cells assay. A cell culture using MC3T3 cell line was accomplished on glass discs (12.5 mm in diameter x 2.0 mm thick) of Composition 5 in a 24-well culture plate. Spots (green in original; not provided) represent the viable cells, and spots (red in original; not provided) represent dead cells. No dead cells (i.e., red images) were visible in any of the FIG. 2 images. FIG. 2A shows the cell culture at day 1 and FIG. 2B shows the cell culture at day 4. For comparison, images of cells cultured in tissue culture-treated (TCT) wells were obtained and shown in FIGS. 2C and 2D (for days 1 and 4 respectively).

The biocompatibility and degradation can be influenced by the composition of the glass. In the disclosed glass compositions, SiO₂ can serve as the primary glass-forming oxide. However, the glasses preferably do not contain too much SiO₂ since the melting temperature (e.g., 200 poise temperature) of pure SiO₂ or high-SiO₂ glasses is too high. Furthermore, the bioactivity of glass will be decreased with high SiO₂ content (see L. L. Hench, Bioceramics, J Am Ceram Soc, 1998, 81:1705-1728).

P₂O₅ can also serves as a network former. Furthermore, the liberation of phosphate ions to the surface of bioactive glasses can contribute to the formation of apatite. The provision of phosphate ions by the bioactive glass increases apatite formation rate and the binding capacity of the bone tissue. In addition, P₂O₅ increases the viscosity of the glass, which in turn expands the range of operating temperatures, and is advantageous to the making the glass.

Alkali oxides (Li₂O, Na₂O, K₂O, Rb₂O, and Cs₂O) can serve as aids in achieving low melting temperatures and low liquidus temperatures. The addition of alkali oxides has been reported to improve bioactivity (see Q. Fu, et al., supra.). Divalent cation oxides (such as alkaline earth oxides) can also improve the melting behavior and the bioactivity of the glass. Particularly, CaO was able to react with P₂O₅ to form apatite when immersed in a simulated body fluid (SBF) or in vivo. The release of Ca²⁺ ions from the surface of the glass can contribute to the formation of a layer rich in calcium phosphate.

Raw materials, equipment, or both, used to produce the compositions of the present disclosure, can introduce certain impurities or components that are not intentionally added, and can be present in the final glass composition. Such materials can be present in the disclosed compositions in minor amounts and are referred to as “tramp materials.”

Disclosed compositions can comprise the tramp materials, typically in trace amounts. Similarly, “iron-free,” “sodium-free,” “lithium-free,” “zirconium-free,” “alkali earth metal-free,” “heavy metal-free,” or like descriptions, mean that the tramp material was not purposefully added to the composition, but the composition may still comprise iron, sodium, lithium, zirconium, alkali earth metals, or heavy metals, etc., but in approximately tramp or trace amounts.

Unless otherwise specified, the concentrations of all constituents recited herein are expressed in terms of weight percent (wt %).

EXAMPLES

The following Examples demonstrate making, use, and analysis of the disclosed compositions and methods in accordance with the above general procedures.

Example 1

Bioactive Glass Melts. Glass compositions listed in Table 1 were prepared by combining the respective batch ingredients, including sand, sodium carbonate, potassium carbonate, calcium metasilicate, magnesia, di-sodium phosphate, in the indicated amounts. The batch source materials were vigorously mixed in a plastic jar using a Turbular mixer. Then they were transferred to a platinum crucible with an internal volume of approximately 650 cc. The crucible was then loaded into an annealing furnace to calcine the batch at 250° C. for 24 hr. The calcined batches were the melted at from 1300 to 1500° C. for 16 hr and then the glass melt was poured on a steel plate, and annealed at from 400 to 500° C.

Example 2

Bioactive Glass Fibers. Glass compositions of Example 1 were drawn into fibers using a directly heated platinum bushing. Glass cullet was loaded into the bushing, and heated up to from 1050 to 1200° C. to obtain a glass melt. The viscosity of the melt was of from 200 to 1500 poise to allow for the formation of a glass drip on the orifice in the bushing. The drip was then pulled by hand to begin forming a fiber. Once a fiber was established the fiber was connected to a rotating pulling/collection drum to continue the pulling process at a constant speed. Using the drum speed (or revolutions per minute RPM) and glass viscosity, the fiber diameter can be manipulated. In general, the faster the pull speed the smaller the fiber diameter that results.

Example 3

Biocompatibility of Bioactive Glass Compositions. Glass discs (12.5 mm in diameter×1 mm thick) were prepared from the annealed patties of Example 1 using a diamond core drill, and then ground polished to a 1.0 micron finish using CeO₂ slurry. All finished parts were cleaned by sonicating in an ultrasonicater for 10 min. Then the discs were placed into wells of 24 well microplates. MC3T3 cells were seeded to each well at a density of 10K/well and cultured for 1, 4, or 7 days in a humid incubator at 37° C./5% CO₂. Calcein AM and ethidium homodimer-1 were used to stain live/dead cells. The cell images were captured under a fluorescent microscope and presented in FIGS. 1.

While various features, elements or steps of particular embodiments can be described using the transitional phrase “comprising,” in alternative embodiments, including those that may be described using the transitional phrases “consisting” or “consisting essentially of,” are possible.

The disclosure has been described with reference to various specific embodiments and techniques. However, many variations and modifications are possible while remaining within the scope of the disclosure. 

What is claimed is:
 1. A method of making a bioactive glass fiber comprising: forming a melt of a glass composition comprising: 50 to 70% SiO₂, 0.1 to 10% Al₂O₃, 5 to 30% Na₂O, 0.1 to 15% K₂O, 0.1 to 15% MgO, 0.1 to 20% CaO, and 5 to 10% P₂O₅, based on a 100 wt % of the glass composition, until the melt has a viscosity of from 200 Poise to 2,000 Poise; and drawing the melt into a drawn glass fiber.
 2. The method of claim 1, wherein the drawn glass fiber has a diameter of from 1 micrometer to 100 micrometers.
 3. The method of claim 1, wherein the drawing the melt into the drawn glass fiber is accomplished continuously.
 4. The method of claim 1, wherein a temperature of the melt is from 1,050° C. to 1,200° C., and is above a glass liquidus temperature by from 10° C. to 200° C.
 5. The method of claim 1, wherein the glass composition comprises: 60 to 70% SiO₂, 15 to 30% Na₂O, 5 to 15% K₂O, 1 to 10% CaO, and 5 to 10% P₂O₅, based on a 100 wt % of the glass composition.
 6. The method of claim 1, wherein the glass composition is free of Al₂O₃, MgO, or both.
 7. A bioactive glass composition comprising: 60 to 70% SiO₂, 15 to 30% Na₂O, 5 to 15% K₂O, 1 to 10% CaO, and 5 to 10% P₂O₅, based on a 100 wt % of the bioactive glass composition.
 8. The bioactive glass composition of claim 7, wherein the bioactive glass composition is free of Al₂O₃, MgO, or both.
 9. The bioactive glass composition of claim 7, further comprising a carrier in an amount of from 5 to 300 wt % by superaddition to the bioactive glass composition to form a bioactive glass formulation.
 10. The bioactive glass composition of claim 7, further comprising a carrier in an amount of from 5 to 300 wt % by superaddition to the bioactive glass composition to form a bioactive glass formulation.
 11. The bioactive glass composition of claim 7, wherein the bioactive glass composition has a biocompatibility of at least one of: a proliferation of a live cell line on a surface of the bioactive glass composition; or a continuous cell number increase of from 0 to 7 days in proximity of the surface of the bioactive glass composition. 